Electric Heat Tracing

INSTALLATION PROCEDURES

1 . a ground-fault protection device is required for all heat tracing circuits. Voltage Indication Lamp (VIL). 1.2 2 Circuit switch with indication lamp (padlockable). TSX. (If applicable) 7 End termination ET-6 and ET-60 for RSX. Bond the metal sheath/braid of the heat tracing cable to a suitable earth terminal. (if applicable) T (EEx d) 3 Thermostat (if applicable) With Terminator ZT (EEx ed) it is possible to connect two heating cables into the thermostat. VSX ET-8 and ET-80 for BSX. 3 tracer cables through the expediter XP Plus and maximal 2 power cables through the side entries. the total number of cables to be connected cannot be more than 4.Electric Heat Tracing Illustration A: Typical Heat Tracing Installation1 1 Power cable. 2. 3 T TED (EEx ed) or TC (IND) T ZT T 4 Junction box. For the standard Thermon junction box JB-K or Terminator. arcing and fire caused by product damage or improper usage installation or maintenance. Due to the risk of electrical shock. 3. 5 6 Heating cable. HPT and FP Notes . KSX. . Suitable for max. . Thermostatic control is recommended for all freeze protection and temperature maintenance heat tracing applications. All heat-traced lines must be thermally insulated. HTSX.

. • Test for absence of voltage with an approved voltmeter (where the voltmeter is tested on a known circuit voltage prior to and immediately following application). and how to recognize and avoid the hazards associated with its operation and maintenance. that the appropriated circuit disconnecting device is indeed open. 3. . • Apply ground-connecting devices rated for the available fault duty where the conductors or circuit parts being deenergized could possible contact other exposed energized conductors or circuit parts.INSTALLATION PROCEDURES Complete Electric Heat Tracing System . and other protective equipment needed to protect employees from potential arc flash and shock hazards identified in the analysis. 2 . and then open the circuit disconnecting device(s). . . its electrical power supply/control equipment. Provide training to create qualified employees capable of understanding the purpose/function of the electrical heat tracing. • Visually verify. . . 0539 0539 0539 0539 0539 0539 0539 0539 0539 0539 0539 II 2 G & D EEx e II T6 II 2 G & D EEx e II T5 II 2 G & D EEx e II T3 II 2 G & D EEx e II T3 II 2 G & D EEx e II T3 II 2 G & D EEx e II T3 02ATEX0132424 (T5 for BSX 10) 02ATEX0152668 02ATEX0152666 02ATEX0120790 02ATEX0148864 02ATEX0152667 (T2 for VSX 20) 02ATEX0132337X II 2 G & D EEx e II T2 To T6 II 2 G EEx ed IIC T2 To T6 LCIE 01ATEX6051X II 2 G EEx edm IIC T2 To T6 LCIE 00ATEX6014X II 2 G EEx edm IIC T2 To T6 LCIE 00ATEX6014X II 2 G EEx e II T1 To T6 LCIE 00ATEX6025 Site Practice . Power-Limiting Heating Cable: HPT™ (refer to Form TEP0011U) 3. 2. Provide protective clothing. • Apply lockout/tagout devices according to a documented and established procedure. personal protective equipment. Types of Heating Cables1 . Refer to the heating cable product specification sheets for temperature ratings as limited by the manufacturer. Treat all electrical conductors and circuit parts as though they are energized until they are placed in an electrically safe work condition by doing the following: • Identify the circuit or equipment to be de-energized and all possible sources of electrical energy supplies to the specific circuit or equipment. Series Constant Watt Heating Cables: TES™ (refer to Form TEP0063U) TESH™ (refer to Form TEP0070U) MIK™ (refer to Form TEP0020U) Notes . 1. Parallel Constant Watt Heating Cable: FP (refer to Form TEP0016U) 4. . • Interrupt the load currents appropriately. Self-Regulating Heating Cables: BSX™ (refer to Form TEP0067U) RSX™ 15 (refer to Form TEP0048U) TSX® (refer to Form TEP0006U) HTSX™ (refer to Form TEP0074U) KSX™ (refer to Form TEP0072U) VSX™ (refer to Form TEP0008U) 2. where possible. 1. • Ground the phase conductors or circuit parts before touching them where the possibility of induced voltages or stored electrical energy exists. 1. .

1. Store in a dry place. Illustration B: Temporary Installation Initial Installation . Electric heat tracing cables are used for freeze protection or temperature maintenance of piping. FP is 19 mm. factory-fabricated series circuits will have an imprinted l. TESH and MI is 5 x OD). 1. elbows and supports as per the applicable drawings. See ‘Types of Heating Cables’ on page 2. Begin temporary installation at the proposed end-ofcircuit location and lay out heating circuit on the pipe. The system installation must also comply with all local and national electrical codes. 1. Compare information on heating cable with packing slip and purchase order to verify receipt of correct shipment. Heat tracing cables may be installed in ordinary (nonclassified) and hazardous (classified) locations depending on the specific cable options and approvals. 2. Identify the heating cable to ensure the proper type and quantity have been received. . Keep ends of heating cable dry and sealed before and during installation Caution: Do not connect power to heating cable while it is still on the reel or in a shipping carton. 2. 3. Before Installing Cable . However. tanks and instrumentation. Be sure all piping and equipment to be traced is completely installed. the information is printed on the jacket below the braid). Refer to Illustration B for temporary installation.D. • While the cable is still on the reel • After installing heating cable • After installation of thermal insulation • Prior to connecting cable to power • As part of a routine maintenance program 2. 1. flanges. allowing extra cable for the power connection and for any splice locations2. 2. and for polymer insulated heating cables. . Applications . for mineral insulated cables. 1. . Minimum bending radius of heating cable is 32 mm (except HPT is 57 mm. The minimum acceptable level should not be less than 20 megohms. Storing and Handling . The cable model number will be visible on parallel heating cables (on braided cables. Termination kits to fabricate a heat tracing circuit are not addressed in detail in these installation procedures. Refer to installation instructions included with cable termination kits or contact Thermon for specific instructions to fabricate heating cable. . Before removing the heating cable from the reel. The cable should be tested with a test voltage of at least 500 Vdc. 2500 Vdc is recommended. Visually inspect materials for damage incurred during shipment. rust and scale with a wire brush and oil and grease films with a suitable solvent. Product certifications and performance of heat tracing system is dependant upon proper installation with certified Thermon components. Proposed End-of-Circuit Location Proposed Power Connection Location Cable Allowance for In-Line Heat Sinks Pipe Support 3 . Surface areas where heat tracing is to be installed must be reasonably clean. The installation must be installed in accordance with the regulations as per the norm EN IEC 60079-14 and IEC 62086-2 for hazardous areas (where applicable). 2. pressure tested and painted (if applicable) 3. Testing should occur at the following stages of installation. Report damages to the carrier for settlement. . a test voltage of 1000 Vdc is recommended. . .Electric Heat Tracing Read and carefully follow all installation procedures before installing a Thermon electric heat tracing system1. . Receiving. Make heating cable allowances for valves. refer to pages 4 and 5 of these installation procedures. . an insulation resistance test should be conducted. tag with pertinent data. Remove dirt. Notes . .

Supports and Flanges . . Elbows: Locate the cable on the outside radius of an elbow to provide sufficient heat to compensate for the added piping material. In winterizing systems. allow two times the length of the pipe support plus an additional 8 cm of heating cable. Thermon highly recommends to isolate the pipe supports from the pipes) 4.INSTALLATION PROCEDURES Installation on Elbows. Pipe Supports: of diameter > 2” require additional heating cable. 2. (8 cm) Illustration E: Pipe Flange Heating Cable Attachment Tape (Typical) 12" Max. Secure the cable to the pipe on each side of the elbow with attachment tape. Illustration C: Pipe Elbow Heating Cable Illustration D: Pipe Support Heating Cable Attachment Tape (Typical) 3" Min. (8 cm) Attachment Tape (Typical) Support Length 3" Min. Heating cable must maintain contact with flange when bending around pipe flanges to compensate for additional heat loss. (30 cm) Note: Flange allowance will vary based on method of insulating flange and adjacent piping. Use approved attachment tape only. . (In process temperature maintenance systems the pipe supports must be isolated from the pipes. Install heating cable in accordance with Illustrations C. 3. Secure heating cable to piping using attachment tape rated at the application temperature. Flanges: Allow cable to be looped around pipe on each side of and adjacent to the flange. D and E below. 1. 4 . Caution: Do not use metal pipe straps or tie wire to attach heating cable.

62) 30 (9.5 (.07) 5 (1.5 (5.91) 2 (.Electric Heat Tracing Installation on Valves and Pumps .27) 16.5 (.76) 2.5 (6.76) 3 (.94) 23 (7.52) 8 (2.52) 5.30) 2 (.30) 1.81) 15 (4.73) 80 (24.5 (5. Install heating cable on valves and pumps utilizing a looping technique (this allows the valve or pump to be removed if required).35) 14 (4.83) 6. 2.11) 51 (15.5 (1. Secure heating cable to piping using attachment tape rated at the application temperature.22) 4 (1.14) 36 (10.38) 4 (1.01) 27 (8. Install heating cable in accordance with Illustrations F and G below.75 (.5 (2.05) 16 (4.37) 5 (1.22) 7 (2.46) 3 (.30) 1 (.30) 1.46) 2 (.5 (.22) 5 (1.19) Valve Type Flanged ft (m) 1 (.97) 42 (12.5 (1.5 (1. 4.03) 19.71) 28 (8.68) 6 (1.5 (1.5 (.36) 40 (12.60) Illustration F: Typical Valve Detail Heating Cable Attachment Tape (Typical) Heating Cable Attachment Tape (Typical) Temporary Loop of Cable on Valve Heating Cable Serpentined on Valve Illustration G: Typical Pump Detail Heating Cable Attachment Tape (Typical) Circuit Layout on Pump Heating Cable Serpentined on Pump 5 .52) 5. Crossing series heating cable over itself should be avoided.5 (.44) 14 (4.5 (1.46) 1. .5 (7.37) 68 (20.5 (.77) 28.02) 54 (16.46) 60 (18.95) 84 (25.61) 2.57) 18 (5.30) 1.5 (.5 (.49) 21.5 (3. Refer to Table 1 for estimated cable requirements for installation on typical valves and pumps. Additional cable is required to provide extra heat at valves.88) 22 (6.14) 36 (10.69) 34 (10.80) Welded ft (m ) 0 0 1 (.13) 9.54) 57 (17.91) 3.61) 2 (.5 (.79) 25 (7.27) 19 (5. 1.05) Pump Type Screwed Flanged ft (m) ft (m) 1 (.22) 4. 3.46) 2 (.68) 7 (2.90) 12.61) 1.76) 3. .5 (1.23) 30 (9.91) 4 (1.15) .13) 8 (2.44) 10 (3.5 (8.89) 46 (14.52) 8 (2.91) 3 (. pumps and miscellaneous equipment to offset the increased heat loss associated with these items.23) 1 (.06) 39 (11.55) 25. Pipe Size in (mm) ½ (12) ¾ (19) 1 (25) 1¼ (32) 1½ (40) 2 (50) 3 (80) 4 (100) 6 (150) 8 (200) 10 (250) 12 (300) 14 (350) 16 (400) 18 (450) 20 (500) 24 (600) 30 (750) Table 1: Valve and Pump Allowances Screwed ft (m) .07) 4 (1.61) 2.22) 5 (1.46) 2 (. Refer to the product specifications sheet for minimum bend radius for the specific cable type.61) 2. Do not exceed bend radius when completing installation.97) 43 (13.53) 33 (10.44) 11 (3.5 (.13) 10 (3.29) 72 (21.76) 4 (1.61) 3 (.98) 7 (2.

However. Refer to Table 2 below to calculate the number of rolls of attachment tape required based on the pipe diameter1. repeat the megger test. • Ml mineral insulated heating cables are typically installed with stainless steel banding. (MI series resistance heating circuits are typically prefabricated at the factory. Before making power connections. 1.9) 3" (80) 150' (45. Sensor Location 90° Temperature Sensor (Typical) 90° 90° Pipe Wall Heating Cable (Typical) Single Cable Installation Dual Cable Installation Heating Cable (Typical) Triple Cable Installation 90° Temperature Sensor (Typical) 90° 4.7) 1¼" (32) 260' (79.4) 8" (200) 70' (21. refer to installation details provided with the project drawings or contact Thermon for additional information regarding installation.1) 20" (500) 25' (7. • If applicable. and for polymer insulated heating cables. a test voltage of 1000 Vdc is recommended. a continuous covering of aluminum foil tape may be required when: • Spray or foam urethane2 thermal insulation is applied. Secure temperature sensor (if required) to pipe utilizing attachment tape. 90° 90° 90° Table 2: Attachment Tape Allowance Pipe Size in (mm) Length of Pipe/ Roll of Tape Ft (m) ½"-1" (12-25) 360' (109.6) 24" (600) 20' (6. The minimum acceptable level should not be less than 20 megohms. Pipe-mounted junction boxes to complete a typical MI circuit connection to power may not be supplied as part of the system.2) 12" (300) 50' (15. 3.7) 4" (100) 120' (36.2) 14" (350) 40' (12. . 2500 Vdc is recommended.) 6.7) 18" (450) 30' (9. . 1. . 5. Illustration H: Heating Cable vs. Complete splice connections (if required) in accordance with the installation instructions provided with the splice kit. 2.INSTALLATION PROCEDURES Completing the Installation . Locate temperature sensor as shown in Illustration H. The cable should be tested with a test voltage of at least 500 Vdc.2) 16" (400) 35' (10. 2. Table 2 assumes circumferential bands every 12" (30 cm) along the length of the process piping. In addition to the circumferential tape requirements.6) 6 . Begin final cable attachment by securing the end-ofcircuit termination kit and working back toward the power supply. These cables may also be installed with heat transfer compound and metal channels.6) 6" (150) 90' (27. • Design requirements dictate the use of aluminum tape to improve heat transfer.0) 2" (50) 180' (54. Notes . Verify exposure temperature of heating cable versus curing temperature of insulation. . Circumferential bands of tape should be installed at maximum 30 cm intervals to keep the cable in proper contact with the pipe.0) 30" (750) 15' (4. for mineral insulated cables. Install power connection kit in accordance to the detailed installation instructions provided with the kit. • Flexible heating cables are to be installed using attachment tape rated at the application temperature.2) 1½" (40) 220' (67.3) 10" (250) 60' (18. • Heat tracing nonmetallic piping.

THERMON . Record all information after conducting test. Thermal Insulation . This should call attention to any damage to the heating cable that may have occurred during the insulation installation. the heating circuit should be connected directly to the switched power feed wiring. heat losses are generally too high to be offset by a conventional heat tracing system. 4. The minimum acceptable level should not be less than 20 megohms. physical damage and helps ensure the proper performance of the heat tracing system. 1. Before installing thermal insulation. This information may be of value for future reference and should be maintained for the historical operating data log. the heating circuit is to be connected in series with the control contacts with a maximum load of 16A. However. In addition to piping and in-line equipment such as pumps and valves. for mineral insulated cables. and for polymer insulated heating cables. valve bonnets. Regardless of the type or thickness of insulation used. a test voltage of 1000 Vdc is recommended. PO Box 609 San Marcos. 3. Megger testing should be conducted. 1. 2500 Vdc is recommended. refer to Thermon’s Maintenance and Trouble Shooting Guide for assistance. in most cases.S. Stabilized design can be used for self-regulating heating cables to assign a lower T-class through the use of the Thermon CompuTrace software or Thermon Engineering. flanges and. If stabilized design is used. The need for properly installed and well-maintained thermal insulation cannot be overemphasized. 5. For pipewall sensing thermostatic control. Stabilized design can be used for power-limiting and constant watt heating cables without a limiting device to determine the T-class through the use of the Thermon CompuTrace software or Thermon Engineering. The cable should be tested with a test voltage of at least 500 Vdc. The cable should be tested with a test voltage of at least 500 Vdc. all heat sinks must be properly insulated. TX 78667-0609 U. Take the values after 15 minutes of energizing. Power connection and end-of-circuit termination kits are designed for each type of cable. If the system fails any test. Without insulation. 6. 7. . and for polymer insulated heating cables. The maximum temperatures provided by Thermon’s CompuTrace software and by Thermon engineering are calculated to the methods and requirements of IEC 62086-2 Cl. 6. . . De-energize circuits affected and make the necessary repairs immediately. hangers. a protective barrier should be installed.com European Headquarters Boezemweg 25 2641 KG Pijnacker PO Box 205 2640 AE Pijnacker The Netherlands Phone: +31 (0) 15-36 15 370 Facsimile: +31 (0) 15-36 15 379 • • • • Corporate Headquarters 100 Thermon Dr. for mineral insulated cables. However. 2. 2. pipe temperature and ambient temperature may be recorded. The Heat Tracing Specialists® www. Final Inspection and Documentation . a test voltage of 1000 Vdc is recommended. 3.Final Connections . 4.7. . the megohmmeter test should be repeated. The pipewall sensing thermostat may require more than one support point. 3.thermon. . 1. 2. . . It is recommended that the circuit be temporarily energized so that the volts. 4. the end user must record the system parameters and the area T-class. The minimum acceptable level should not be less than 20 megohms. Follow the circuit fabrication instructions for the specific cable type. and keep these records for the time the heating cable is in operation. For ambient controlled power.A. This includes pipe supports. amps. Phone: +1 512-396-5801 Facsimile: +1 512-396-3627 • • • Form PN 50207U-1004 © Thermon Manufacturing Co. After the installation of the thermal insulation and weather barrier but BEFORE ENERGIZING THE HEATING CIRCUIT. . 2500 Vdc is recommended. . Inspect system on a regular basis at least once per year. substitutions should not be made. This protects the insulation from moisture intrusion. Seal around all penetrations through the thermal insulation. The power connection junction box can be pipe mounted and/or wall mounted. megger testing should be conducted.

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